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THERMACUT EX-TRAFIRE 45HD Operator'S Manual Download Page 31

EX-TRAFIRE

®

45SD

Operator Manual, Revision T-5

3-31

Activating an industrial isolated module 

with an external power supply

Notes:

1�   Isolated input module, 

provided by the user�

2�   24 VDC power supply to be 

provided by the user�

ISOLATED INPUT 
MODULE�

Installation of the machine interface cable

 must be performed by a certified electrician or 

competent person�  
To install a machine interface cable:

1� Turn OFF the power and disconnect the power cord� 
2� Remove the machine interface receptacle’s cover from the rear of the power supply� 
3� Connect the interfece cable to the power supply�

Summary of Contents for EX-TRAFIRE 45HD

Page 1: ...BEFORE SWITCHING ON OR OPERATING THE SYSTEM READ THIS MANUAL BECOME FAMILIAR WITH THE CONTENT KEEP THE MANUAL LOCAL TO THE JOB SITE WITH EASY ACCESS TO ALL PERSONNEL THE SYSTEM IS TO BE USED FOR META...

Page 2: ...c field can affect pacemakers 8 Plasma cutting can cause interference 8 Safety Sticker 9 SECTION 2 SPECIFICATIONS 2 10 Dimensions and weight of the plasma arc power supply 2 11 Specifications plasma a...

Page 3: ...isplay details 4 36 Setting of power supply 4 37 1 Mode selection 4 37 2 Cutting parameters 4 38 3 Two variants of cutting torch 4 38 Rear view Turn ON 4 39 Rear panel detail 4 39 Cutting preparation...

Page 4: ...ION 7 ADITIONAL ORDERING INFORMATION 7 63 SECTION 8 TROUBLESHOOTING 8 64 SECTION 9 ACCESSORIES 9 69 Filter EX Compressed Air Filter with replacement filter cartridge 9 69 Filter EX Quick Connect Coupl...

Page 5: ...ause fire or explosion 7 Electric shock can kill 7 Plasma arc can injure 7 Flying sparks arc spray can cause injury fire or explosion 7 Hot parts can cause severe burns 7 Smoke and gases can be hazard...

Page 6: ...al cutting gouging processes the area around the cutting process should be kept free from flammables Use face shield safety glasses with side protection Wear flame resistant clothing footwear and hand...

Page 7: ...ses liquids and materials remove prior to cutting as they present a fire risk EXPLOSION PREVENTION Do not cut in areas containing explosives flammable gases or vapors Do not place the system on over o...

Page 8: ...ASES CAN BE HAZARDOUS Work in a confined space only if it is well ventilated or while wearing an air supplied respirator The smoke and gases from the cutting gouging process can displace air and lower...

Page 9: ...any movement If not reasseble it and put these parts together again EX TRAFIRE 45HD Operator Manual Revision T 1 1 Hand torch consumables installation WARNING Plasma arc is generated immediately when...

Page 10: ...plasma arc power supply EX TRAFIRE 45SD 1 phase 2 12 Specifications plasma arc power supply EX TRAFIRE 45SD 3 phase 2 13 Specifications Torches FHT EX 45TTH and FHT EX 45TTM 2 14 Dimensions and config...

Page 11: ...t of plasma arc power supply without torch 12 7 kg EX TRAFIRE 45SD Is a portable plasma arc cutting system Has been designed for Handheld Cutting Mechanised Cutting and Gouging Uses compressed air or...

Page 12: ...rating of power cord eff effective rms root mean square I1rms I1eff I1rms I1eff 36 7 A 23 2 A 33 A 23 3 A This equipment conforms to IEC 60974 1 IEC 60974 10 Isolation class F IP Code Degree of protec...

Page 13: ...urrent I2 for cutting only I1eff I1 X used to determine rating of power cord eff effective rms root mean square I1rms I1eff 16 2 A 14 4 A This equipment conforms to IEC 60974 1 IEC 60974 10 Isolation...

Page 14: ...ons IP3X EN 60 529 Type of connection TCS torch connection system 13 pin Voltage rating 500V peak value Rated value of control leads trigger and cap sensor 42 VAC 0 1 1A Standard lenght other length a...

Page 15: ...ual Revision T 5 2 15 Machine torch FHT EX 45TTM Shielded configuration using machine shield Dimensions and configuration Shielded configuration using drag shield Unshielded configuration using deflec...

Page 16: ...d standards EMC LVD C Tick Mark This mark signifies compliance with appropriate Australian EMC standard EAC Mark This mark indicates products that conform to all technical regulations of the Eurasian...

Page 17: ...pressure fault Cutting mode Direct Current DC power The power supply is working Gouging mode Indicates pressing of torch trigger or connection of pins 3 4 in the CNC connector Indicates arc transfer A...

Page 18: ...lead 3 22 Installation of three phase mains power lead 3 22 Torch installation step by step 3 23 Working ground cable installation step by step 3 26 Plasma gas supply 3 27 Additional gas filtration 3...

Page 19: ...rier immediately take photographs of the packaging and areas of damage on the system Inform Authorized Supplier who will provide copies of relevant documentation For further assistance contact Custome...

Page 20: ...Use slow blow fuses with a suitable capacity in accordance with local and national electrical codes Connecting to an engine drive power generator When using an engine drive generator to power the EX...

Page 21: ...n of the user The mains power lead shall comply with local and national codes of practice The mains power lead should be installed by a certified electrician See the length requirements listed below R...

Page 22: ...e the EX TRAFIRE 45SD use a plug that complies with national and local codes of practice A certified electrician or competent person should connect the mains power lead to the plug Installation of thr...

Page 23: ...orch installation step by step 1 TURN OFF the power supply OFF 0 Turn OFF ON I Turn ON Torch latch key position of TCS Torch Connection System plug 2 Torch connection power supply location 45SD Single...

Page 24: ...plug Latch with key position TCS latch with key Torch TCS plug Latch with key position 4 Torch connection 1st step place the TCS latch with key into the TCS power supply socket The TCS latch with key...

Page 25: ...g into the TCS socket The torch TCS plug must be locked in the TCS socket properly with the key nose 6 Torch connection proper position of the TCS plug in the TCS socket WARNING FHT EX 45TTH TTM torch...

Page 26: ...ual Revision T 5 3 26 Working ground cable installation step by step 1 TURN OFF the power supply 2 Push the connector of work clamp cable into the appropriate socket 3 Turn the connector clockwise to...

Page 27: ...1 mg m3 class 2 ref ISO 8573 Air max dewpoint 3 C class 4 ref to ISO 8573 Purity 99 99 Gas quality Clean moisture free without oil Note A poor quality gas supply has a detrimental effect on cut speed...

Page 28: ...k disconnect fitting Gas supply installation Connect the air line hose as follows 45SD Single phase 45SD Three phase Gas pressure adjustment 1 Open the side door for gas regulator 2 Switch over operat...

Page 29: ...start system motion Ground Voltage divider Type Input Output Ground Output Note Normally open Requires a dry contact to close it Normally open Dry contact with maximum capacity of 120 VAC 1 A Divider...

Page 30: ...rator Manual Revision T 5 3 30 Activating an external DC coil with an external power supply Activating an external AC coil with an external power supply Use a diode 1N4007 if the voltage is 24 VDC 24...

Page 31: ...supply to be provided by the user ISOLATED INPUT MODULE Installation of the machine interface cable must be performed by a certified electrician or competent person To install a machine interface cabl...

Page 32: ...ide with help of the screw with hexagonal head Use the hexagonal wrench Tighten by hand The hand shield defines the required torch to workpiece distance Screw with hexagonal head Hexagonal wrench Work...

Page 33: ...the cutting guide point in the same direction as the torch handle see picture below Now the torch with the cutting guide is ready to cut Radius bar 7 Screw in the radius bar into the threaded hole in...

Page 34: ...TRAFIRE 45SD Operator Manual Revision T 5 3 34 8 Use the following fasteners to anchor the radius bar to the center of the circle Magnetic base assembly Straight locking pin Free centering straight p...

Page 35: ...nstallation 4 41 Operating the hand torch 4 42 Operating the torch safety trigger 4 42 Fit the work clamp 4 43 Edge start cutting 4 43 Hand torch cutting technique 4 44 Piercing 4 45 Gouging 4 46 Alig...

Page 36: ...pe 9 Indicates pressing of torch trigger or connection of pins No 3 4 in the CNC connector 10 Indicates arc transfer 11 Cutting parameters air pressure output voltage the detected length of torch 12 C...

Page 37: ...6 bar Setting of power supply The LCD screen contains two menus In the first menu the cutting current Amperage and the operation modes can be adjusted Turn the regulator knob left or right to set cut...

Page 38: ...rametrs illuminate Press on multifunction knob briefly to set bar MPa or psi 3 Two variants of cutting torch hand torch machine torch output voltage visible after the arc transfer autodetection autode...

Page 39: ...panel detail Rear view Turn ON 45SD Single phase 45SD Three phase Rear panel Switch ON Switch ON 45SD Single phase 45SD Three phase 1 Power supply switch 2 Mains power lead 3 CNC interface connector...

Page 40: ...Arc is extinguished Release the torch trigger Post flow 20 45 s according to cutting current Note During the automatic start up gas and system check the torch trigger will not function normal 1 Firml...

Page 41: ...aining cap 2 Insert the swirl ring into the assembly retaining cap nozzle 3 Insert the electrode into the assembly retaining cap nozzle swirl ring 4 Screw on this whole assembly retaining cap nozzle e...

Page 42: ...ill cut quickly through gloves and skin Make sure the power supply is switched off before changing consumables Keep away from the torch tip Do not hold the piece that is to be cut and keep your hands...

Page 43: ...good contact and remove surface contaminants DO NOT fit the work clamp to the material that will be severed scrap Fit the work clamp as close as possible to the cutting area to minimise exposure to e...

Page 44: ...w After the torch trigger is released the gas will continue to flow up to 45 seconds according to adjusted cutting current to cool the torch and consumables Note The torch will be ready to restart by...

Page 45: ...hat the torch is aimed Aim the torch away from yourself and others Hold the torch so that the nozzle is within 3 mm of the work piece before firing Hold the torch at an angle to the work piece depress...

Page 46: ...iece before firing Hold the torch at an angle of 45 to the work piece Depress the trigger to start the pilot arc Transfer the arc to the work piece Maintain an approximate angle of 45 to the work piec...

Page 47: ...taining cap 2 Insert the swirl ring into the assembly retaining cap nozzle 3 Insert the electrode into the assembly retaining cap nozzle swirl ring 4 Screw on this whole assembly retaining cap nozzle...

Page 48: ...tial Pierce Height Shield Pierce Delay Time Recommended Speed Maximum Speed Kerf Width Best Quality Settings Standard Quality Settings Cut Speed Voltage Cut Speed Voltage mm mm mm seconds mm min Volts...

Page 49: ...atory testing Actual cutting speeds may vary based on different cutting applications Cut charts are a guide for mechanized cutting individual systems can be fine tuned to achieve optimum cut quality U...

Page 50: ...e Distance Initial Pierce Height Shield Pierce Delay Time Recommended Speed Maximum Speed Kerf Width Best Quality Settings Standard Quality Settings Cut Speed Voltage Cut Speed Voltage mm mm mm second...

Page 51: ...the speeds that must be achieved to be rated at that thickness Maximum cut speeds are the results of intensive laboratory testing Actual cutting speeds may vary based on different cutting application...

Page 52: ...EX TRAFIRE 45SD Operator Manual Revision T 5 5 52 SECTION 5 MAINTENANCE Routine maintenance 5 53 Consumable parts inspection 5 54 Purging draining of the built in filter 5 55...

Page 53: ...examination of the torch check the torch trigger safety mechanism check for signs of cracking in the torch body or exposed wires Immediately replace the mains power lead plug if damaged Immediately r...

Page 54: ...zzle Retaining Cap Nozzle Out of round orifice indicates worn condition Replace nozzle Good orifice Worn orifice Swirl Ring Damage or contamination of external surface Replace swirl ring Internal hole...

Page 55: ...5 55 Purging draining the built in filter This power supply is equipped with built in float type auto drain filter Do not cover outflow drain hole located on the bottom of the power supply see the pic...

Page 56: ...FHT EX 45TTH Hand Torch Assembly 6 57 FHT EX 45TTH Hand Torch Components 6 58 FHT EX 45TTH Hand Torch Consumables 6 59 FHT EX 45TTM Machine Torch Assembly 6 60 FHT EX 45TTM Machine Torch Components 6...

Page 57: ...DESCRIPTION EX 2 133 001 FHT EX45TTH DEMO Hand Torch Assembly w consumables TCS13 EX 2 101 001 FHT EX45TTH Hand Torch Assembly w o consumables w 5m Lead TCS13 EX 2 103 001 FHT EX45TTH Hand Torch Asse...

Page 58: ...Lower 6 EX 0 325 010 Retaining Ring Outer circlip ring 7 EX 0 325 009 O Ring fitted in the TCS plug 8 EX 0 325 005 Male Crimp Pin for TCS Plug 9 EX 0 323 001 TCS13 Plug Body 10 EX 2 302 001 Hand Torc...

Page 59: ...bles Configuration 45 A Item Part No DESCRIPTION 1 EX 2 401 201 Electrode 2 EX 2 404 201 Swirl Ring 3 EX 2 409 201 Nozzle 4 EX 2 415 201 Retaining Cap 5 EX 2 419 201 Hand contact Shield 6 EX 2 409 202...

Page 60: ...233 001 FHT EX45TTM DEMO Machine Torch Assembly w consumables TCS13 EX 2 202 001 FHT EX45TTM Machine Torch Assembly w o consumables w 5m Lead TCS13 EX 2 204 001 FHT EX45TTM Machine Torch Assembly w o...

Page 61: ...d TCS13 3 EX 5 318 001 TCS Plug Spring Strain Relief 4 EX 0 325 015 TCS Clam Shell Screw Kit incl 4 screws 5 EX 0 325 002 TCS Clam Shell Upper 6 EX 0 325 001 TCS Clam Shell Lower 7 EX 0 325 010 Retain...

Page 62: ...2 EX 2 404 201 Swirl Ring 3 EX 2 409 201 Nozzle 4 EX 2 415 202 Retaining Cap w IHS Tab 5 EX 2 415 201 Retaining Cap 6 EX 2 421 201 Machine Shield 7 EX 2 428 011 IHS Ohmic Clip 8 EX 2 423 211 Deflector...

Page 63: ...1x110 230V Hand System FHTEX45 TTH 15m H Starter Kit 15 m EX TRAFIRE 45SD Mechanized Plasma Cutting Systems Part No DESCRIPTION Length EX 2 011 008 EX TRAFIRE 45SD CE 3x400V Machine System FHTEX45 TT...

Page 64: ...lace the main power switch Note The fan turns ON and OFF automatically The fan may not run when the plasma arc power supply is switched on The error code H06 appears Over temperature OT Fan fault Ensu...

Page 65: ...or missing Install the consumables correctly Dirt inside the torch Remove all consumables clean the inside of the torch Reassemble in correct order When switching cutting modes press the torch trigge...

Page 66: ...e clamp and work piece Make sure that work lead has a good connection to a clean and dry area of work piece Incorrect distance between the torch and the work piece Maintain correct distance between th...

Page 67: ...f material to be cut Consumables fault Consumables are worn Inspect consumables see section Consumable part inspection Incorrect cutting technique Poor cut quality Adjust the cutting current Amperage...

Page 68: ...munication error remote control H11 Missing phase or no input voltage single phase power supply only H13 Air pressure alarm L The input pressure is too low H The input pressure is too high H04 After p...

Page 69: ...0 60 C Size Pipe NPT Dimension 5 2 7 9 132 200 mm This filter does not fall under the specification of pressure equipment and requires no revision Advantages of using the Filter EX Compressed Air Filt...

Page 70: ...Plug with female thread G 1 4 EX 0 802 001 DN 7 2 ES Quick Connect Plug with male thread G 1 4 EX 0 802 002 DN 7 2 ES Quick Connect Coupling with male thread G 1 4 CNC interface EX 0 803 001 CNC Inter...

Page 71: ...guide kit for FHT EX 105RTXH 105TTH 45TTH EX 5 801 002 This Circle cutting guide kit for hand held cutting obtains Circle cutting attachment Cutting guide Radius bar mm 250 Radius bar mm 400 Magnetic...

Page 72: ...EX TRAFIRE 45SD Operator Manual Revision T 5 10 72 SECTION 10 POWER SUPPLY BLOCK DIAGRAM Power supply block diagram 45SD Single phase 45SD Three phase...

Page 73: ...ormation on the recycling of this product refer to manufacturer who will be able to handle the disposal for you or refer to your local authority domestic waste processing organization or store where y...

Page 74: ...e purpose arising out of the Contract otherwise for usual purpose 2 The warranty period is valid from the date the goods are delivered to the buyer par 5 1 5 2 of the GBC 3 Par 3 4 and the following o...

Page 75: ...EX TRAFIRE 45SD Operator Manual Revision T 5 12 75 Notes...

Page 76: ...EX TRAFIRE 45SD Operator Manual Revision T 5 12 76 Notes...

Page 77: ...EX TRAFIRE 45SD Operator Manual Revision T 5 12 77 Notes...

Page 78: ...t Quality Settings Voltage 122 V e Page 6 57 New Part No of item 5 from EX 5 419 201 Hand contact Shield to EX 2 419 201 f Page 7 66 Changes in error codes charter g Page 11 71 New page of Warranty 3...

Page 79: ...hr THERMACUT HUNG RIA KFT Pet fi S ndor utca 37 atd 2500 Esztergom HUNGARY Tel 36 33 502 090 1 Fax 36 33 400 004 E mail info thermacut hu www thermacut hu THERMACUT SLOVAKIA S R O M R tef nika 14 942...

Page 80: ...vsk 574 Ma atice 686 01 Uhersk Hradi t Czech Republic www thermacut cz sales thermacut cz THERMACUT FHT EX and EX TRAFIRE are registered trademarks of THERMACUT k s and may be registered in Czech Repu...

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